Data acquisition system for condition-based maintenance

• US 8,082,115 B2
• Filed: 11/16/2010
• Issued: 12/20/2011
• Est. Priority Date: 11/16/2009
• Status: Active Grant

• Current Assignee: Rockwell Collins, Inc. (Rtx Corporation)
• Original Assignee: NRG System Inc
• Inventors: Bechhoefer, Eric R., Taylor, John T.
• Primary Examiner(s): Le, John H
• Application Number:
  US12/947,415
• Publication Number:
  US 20110125419A1
• Time in Patent Office: 399 Days
• Field of Search: 702/34, 702/113, 702/182, 702/189, 702/188, 290/44, 290/55, 416/37, 416/40, 700/286, 700/287, 700/291, 731/68, 714/4.4
• US Class Current: 702/34
• CPC Class Codes: F03D 17/00 Monitoring or testing of wind motors, e.g. diagnostics testing during commissioning of wind motors F03D13/30
• CPC Class Codes: F03D 7/047 characterised by the controller architecture, e.g. multiple processors or data communications
• CPC Class Codes: F05B 2240/96 as part of a wind turbine farm
• CPC Class Codes: F05B 2270/326 Rotor angle
• CPC Class Codes: F05B 2270/332 Maximum loads or fatigue criteria
• CPC Class Codes: F05B 2270/803 Sampling thereof
• CPC Class Codes: G01M 13/00 Testing of machine parts
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06
• CPC Class Codes: Y02E 10/72 Wind turbines with rotation axis in wind direction
• CPC Class Codes: Y02P 80/20 using renewable energy

Abstract

Generally, a system and method consistent with the present disclosure may provide a relatively low cost, relatively robust data acquisition and analysis system useful for condition-based maintenance. The system may be useful for condition-based maintenance in industrial applications, e.g., of equipment and/or machinery. The industrial monitoring system may be used, for example, to monitor a condition of rotating machinery, e.g., a wind turbine. The system and method may include data analysis that may be useful for anticipating a need for maintenance, repair and/or replacement of one or more components.

Claims

1. A wind farm comprising:

a plurality of wind turbines, each wind turbine configured to generate electrical energy from wind; and

a plurality of wind turbine data acquisition systems, each of said plurality of wind turbine data acquisition systems being mounted on a separate associated one of said plurality of wind turbines and each data acquisition system comprising;

a plurality of sensors, each of said plurality of sensors being directly coupled to a separate respective component of said separate associated one of said plurality of wind turbines and configured to detect a parameter associated with a condition of said separate respective component or a component indirectly coupled thereto and to provide sensor data based at least in part on the parameter;

a plurality of separate interface modules, each of said plurality of separate interface modules being coupled to a separate associated one of said plurality of sensors and being configured to receive the sensor data from said separate associated one of said plurality of sensors, to analyze the sensor data, and to generate module output data based at least in part on the sensor data, said module output data comprising a representation of the condition of said separate respective component or said component indirectly coupled thereto;

a local data concentrator coupled to each of said plurality of separate interface modules, the local data concentrator configured to provide media access control (MAC) for one or more of said plurality of interface modules, to transmit commands to one or more of the plurality of interface modules, to receive module output data from one or more of the plurality of interface modules and to provide the received module output data to a server; and

a serial bus configured to couple the plurality of interface modules and the local data concentrator,

wherein the server is configured to provide an estimate of a remaining useful life of a selected one of said separate respective components or a component indirectly coupled thereto of a selected one of said plurality of wind turbines to a user based at least in part on a representation of the condition of the selected one of said separate respective components or said component indirectly coupled thereto.

2. The wind farm according to claim 1, wherein one of said plurality of sensors is a tachometer configured to detect a rotational speed of a separate respective component or a component indirectly coupled thereto of the wind turbine and another one of said plurality of sensors is an accelerometer configured to detect vibration of a separate respective component or a component indirectly coupled thereto.

3. The wind farm according to claim 1, wherein the selected one of said separate respective components or said component indirectly coupled thereto of the selected one of said plurality of wind turbines is a shaft, a bearing or a gear.

4. The wind farm according to claim 1, wherein the serial bus is a daisy chain and each of said plurality of interface modules is connected to at most two other interface modules.

5. The wind farm according to claim 1, wherein the serial bus is configured to carry power from the local data concentrator to the plurality of interface modules.

6. An apparatus comprising:

a wind turbine configured to generate electrical energy from wind, the wind turbine comprising a separate associated one of a plurality of wind turbine data acquisition systems, the separate associated one of said plurality of data acquisition systems comprising;

a plurality of sensors, each of said plurality of sensors being directly coupled to a separate respective component of said wind turbine and configured to detect a parameter associated with a condition of said separate respective component or a component indirectly coupled thereto and to provide sensor data based at least in part on the parameter;

a plurality of separate interface modules, each of said plurality of separate interface modules being coupled to a separate associated one of said plurality of sensors and being configured to receive the sensor data from said separate associated one of said plurality of sensors, to analyze the sensor data and to generate module output data based at least in part on the received sensor data, said module output data comprising a representation of the condition of said separate respective component or said component indirectly coupled thereto;

a local data concentrator coupled to each of said plurality of separate interface modules, the local data concentrator configured to provide media access control (MAC) for one or more of said plurality of interface modules, to transmit commands to one or more of the plurality of interface modules, to receive module output data from one or more of the plurality of interface modules and to provide the received module output data to a server; and

a serial bus configured to couple the plurality of interface modules and the local data concentrator,

wherein the server is configured to provide an estimate of a remaining useful life of a selected one of said separate respective components or a component indirectly coupled thereto of the wind turbine to a user based at least in part on a representation of the condition of the selected one of said separate respective components or said component indirectly coupled thereto.

7. The apparatus according to claim 6, wherein one of said plurality of sensors is a tachometer configured to detect a rotational speed of a separate respective component or a component indirectly coupled thereto of the wind turbine and another one of said plurality of sensors is an accelerometer configured to detect vibration of a separate respective component or a component indirectly coupled thereto.

8. The apparatus according to claim 6, wherein the selected one of said separate respective components or said component indirectly coupled thereto is a shaft, a bearing or a gear.

9. The apparatus according to claim 6, wherein the serial bus is a daisy chain and each of said plurality of modules is connected to at most two other interface modules.

10. The apparatus according to claim 6, wherein the serial bus is configured to carry power from the local data concentrator to the plurality of interface modules.

11. A method of determining an estimate of a remaining useful life of a monitored component of a wind turbine, the method comprising:

providing a plurality of wind turbine data acquisition systems, each of said plurality of wind turbine data acquisitions systems being mounted on a separate associated one of a plurality of wind turbines, each data acquisition system comprising;

a plurality of sensors, each of said plurality of sensors being directly coupled to a separate respective component of said wind turbine; and

a plurality of separate interface modules, each of said plurality of separate interface modules being coupled to a separate associated one of said plurality of sensors and being configured to receive sensor data from said separate associated one of said plurality of sensors;

detecting a parameter associated with a condition of a selected one of the separate respective components or a component indirectly coupled thereto using an associated one of said plurality of sensors and providing sensor output data from said associated one of said plurality of sensors to a separate associated one of said plurality of interface modules based at least in part on the parameter;

analyzing the sensor data;

generating module output data based at least in part on the sensor output data, said module output data comprising a representation of the condition of said selected one of said separate respective components or said component indirectly coupled thereto;

providing the module output data to a local data concentrator in response to a command from the local data concentrator, said local data concentrator being coupled to each of said plurality of separate interface modules and being configured to provide media access control (MAC) for one or more of said plurality of interface modules;

providing the module output data to a server; and

estimating the remaining useful life of the selected one of said separate respective components or said component indirectly coupled thereto based at least in part on a representation of the condition of the selected one of said separate respective components or said component indirectly coupled thereto,

wherein the wind turbine is configured to generate electrical energy from wind.

12. The method according to claim 11, wherein the analyzing is performed by said separate associated one of said plurality of modules.

13. The method according to claim 11, wherein the analyzing comprises performing a transform to determine a frequency spectrum based on the sensor output data, the frequency spectrum associated with the condition of the wind turbine and further comprising determining statistics based, at least in part, on the frequency spectrum, wherein the statistics are associated with the condition of the selected one of said separate respective components or said component indirectly coupled thereto.

14. The method according to claim 11, wherein the analyzing comprises determining a vector of average sensor output data for a time period corresponding to a revolution of the selected one of said separate respective components or said component indirectly coupled thereto and further comprising determining statistics, based, at least in part, on the vector of average sensor output data.

15. The method according to claim 11, further comprising determining a condition indicator, wherein the condition indicator corresponds to a probability distribution of the detected parameter for a sample of components of known good wind turbines.

16. The method according to claim 15, further comprising determining a health indicator based, at least in part, on at least one condition indicator, wherein the health indicator represents a current condition of the selected one of said separate respective components or said component indirectly coupled thereto.

17. The method according to claim 16, further comprising scaling the health indicator so that a threshold indicating no longer good corresponds to a common reference of health indicators of other monitored components of the wind turbine.